More organizations now find that their stakeholders demand increased
accountability and transparency on sustainability-related issues.
Meanwhile, corporations’ intricate global operations create more
complicated challenges for any EHSQ compliance team. An EHSQ compliance
platform must assist, not hinder, organizations who need to locate those
“pain points.” Such a system must be centralized yet multifunctional;
offer data management and analysis for all layers of an organization; be
easily accessible yet secure, and manage and transform data in various
formats.
o How to improve energy efficiency initiatives throughout your
organization
o Monitor EHSQ compliance, identify opportunities for improvement, and
achieve advancement in EHSQ performance.
o How an effective EHSQ platform can address various regional and
business cultures-- how to address any resistance within your
organization while gaining increased buy-in Modern Process Plants, especially fertilizer plants are designed for flexible production and maximum recovery of energy. Provision of a Distributed Control System (DCS) along with an Advanced Process Control (APC) philosophy can serve this purpose. The objectives of APC implementation in a Gas based Ammonia Plant are as follows:
Minimization of specific energy consumption.
Stabilization of plant load even during fluctuations in variables such as
Natural gas pressure, flow or quality.
Precise control of “Steam to Carbon” ratio in the Primary Reformer for
steam economy.
Optimum control of Oxygen in the Flue Gas.
Control of Synthesis gas quality i.e. the Hydrogen to Nitrogen Ratio.
Accurate control of Methane slippage from the Primary and Secondary
Reformers..
Risk Based Inspection (RBI) Programme
The main aim of the Risk Based Inspection programme is to;
- Maximize safety by evaluating risks for individual equipments/accessories
and recommend methods to reduce risks.
- Optimize productivity by optimizing plant shut down timings
- Optimize inspections, testing and maintenance to improve plant
reliability.
- Improve the understanding of the condition of plant hardware and its
management for long term plant operation.
- Make optimal use of resources through a risk based approach.
Equipment that should be covered in the RBI programme are;
- Furnaces
- Reaction vessels
- Heat exchangers
- Boilers
- Storage tanks/Vessels
- Piping and Pressure Relief valves
Preparation of comprehensive lists of pressure equipment based on criticality in terms of services and set up inspection programme accordingly
- Prioritize the pressure equipment so that the assessments to be carried out enable the major outcomes from the critical plant to be reported as early as possible.
- Develop process loops for piping such that each process loop has the same environment and similar risk exposure.
- Complete a risk-based assessment so that meaningful profiles of failure risk, failure likelihood and failure consequence can be established for each “nominated”
pressure item or process loop in the ammonia plant.
- Prepare inspection programmes for pressure equipment and piping to ensure these items of plant are effectively operated, maintained and their condition assessed.
- Recommend actions, which will be needed to be carried out to ensure safe
& reliable operation of the plant prior to and after planned shutdown.
- Use of proprietary Reliability Management System (RMS) software of the
Vendor who will be entrusted to carryout the study.
- Recommend preliminary scope of work and period of the planned upcoming
shutdown.
A Risk based Inspection study helps to standardize the inspection
procedures to optimize production and time span for planned shutdown.
b. Improving Plant Reliability through Corrosion Monitoring
Corrosion attacks can reduce equipment performance and lead to
unexpected failures and plant shut downs. Corrosion attack of process
equipments may be external or internal. External attack is by ambient
environment whereas internal attack is caused by process fluid handled
inside. Corrosion monitoring is an essential input in Residual Life
Assessment and Aging Management Programme.
Corrosion monitoring techniques are;
- Methods that indirectly measure parameters related to corrosion and
inter corrosion
behavior from some model of corrosion process, e.g. electrochemical
potential, pH and temperature.
- Methods that directly measure corrosion behavior, e.g.,
Non-destructive Inspection,
Material Test Coupons, Galvanic Currents etc.
-- Corrosion Monitoring Techniques:
Direct Measurements
• Non Destructive Inspection (NDI)
• Electrical Resistance (ER) Probes
• Material Test Coupons
• Galvanic Currents
• Cyclic Potentiodynamic Polarization (CPP)
• Linear Polarization Resistance
• Electro Chemical Noise (EN)
• Electrochemical Impedance Spectroscopy (EIS)
Indirect Measurements
• Potential
• Biological Count
• Hydrogen
• pH
• Temperature
• Conductivity
• Specific Ions
Periodic assessment is the most common method of corrosion monitoring
and can help to:
• Evaluate materials performance under specific service conditions
• Aid in proper material selection
• Evaluate and control the production process
• Provide necessary data for Residential Life Assessment
c. Improving Plant Reliability by Conducting Regular Safety Audits
BY Dr. Amar Nath Giri
accountability and transparency on sustainability-related issues.
Meanwhile, corporations’ intricate global operations create more
complicated challenges for any EHSQ compliance team. An EHSQ compliance
platform must assist, not hinder, organizations who need to locate those
“pain points.” Such a system must be centralized yet multifunctional;
offer data management and analysis for all layers of an organization; be
easily accessible yet secure, and manage and transform data in various
formats.
o How to improve energy efficiency initiatives throughout your
organization
o Monitor EHSQ compliance, identify opportunities for improvement, and
achieve advancement in EHSQ performance.
o How an effective EHSQ platform can address various regional and
business cultures-- how to address any resistance within your
organization while gaining increased buy-in Modern Process Plants, especially fertilizer plants are designed for flexible production and maximum recovery of energy. Provision of a Distributed Control System (DCS) along with an Advanced Process Control (APC) philosophy can serve this purpose. The objectives of APC implementation in a Gas based Ammonia Plant are as follows:
Minimization of specific energy consumption.
Stabilization of plant load even during fluctuations in variables such as
Natural gas pressure, flow or quality.
Precise control of “Steam to Carbon” ratio in the Primary Reformer for
steam economy.
Optimum control of Oxygen in the Flue Gas.
Control of Synthesis gas quality i.e. the Hydrogen to Nitrogen Ratio.
Accurate control of Methane slippage from the Primary and Secondary
Reformers..
Risk Based Inspection (RBI) Programme
The main aim of the Risk Based Inspection programme is to;
- Maximize safety by evaluating risks for individual equipments/accessories
and recommend methods to reduce risks.
- Optimize productivity by optimizing plant shut down timings
- Optimize inspections, testing and maintenance to improve plant
reliability.
- Improve the understanding of the condition of plant hardware and its
management for long term plant operation.
- Make optimal use of resources through a risk based approach.
Equipment that should be covered in the RBI programme are;
- Furnaces
- Reaction vessels
- Heat exchangers
- Boilers
- Storage tanks/Vessels
- Piping and Pressure Relief valves
Preparation of comprehensive lists of pressure equipment based on criticality in terms of services and set up inspection programme accordingly
- Prioritize the pressure equipment so that the assessments to be carried out enable the major outcomes from the critical plant to be reported as early as possible.
- Develop process loops for piping such that each process loop has the same environment and similar risk exposure.
- Complete a risk-based assessment so that meaningful profiles of failure risk, failure likelihood and failure consequence can be established for each “nominated”
pressure item or process loop in the ammonia plant.
- Prepare inspection programmes for pressure equipment and piping to ensure these items of plant are effectively operated, maintained and their condition assessed.
- Recommend actions, which will be needed to be carried out to ensure safe
& reliable operation of the plant prior to and after planned shutdown.
- Use of proprietary Reliability Management System (RMS) software of the
Vendor who will be entrusted to carryout the study.
- Recommend preliminary scope of work and period of the planned upcoming
shutdown.
A Risk based Inspection study helps to standardize the inspection
procedures to optimize production and time span for planned shutdown.
b. Improving Plant Reliability through Corrosion Monitoring
Corrosion attacks can reduce equipment performance and lead to
unexpected failures and plant shut downs. Corrosion attack of process
equipments may be external or internal. External attack is by ambient
environment whereas internal attack is caused by process fluid handled
inside. Corrosion monitoring is an essential input in Residual Life
Assessment and Aging Management Programme.
Corrosion monitoring techniques are;
- Methods that indirectly measure parameters related to corrosion and
inter corrosion
behavior from some model of corrosion process, e.g. electrochemical
potential, pH and temperature.
- Methods that directly measure corrosion behavior, e.g.,
Non-destructive Inspection,
Material Test Coupons, Galvanic Currents etc.
-- Corrosion Monitoring Techniques:
Direct Measurements
• Non Destructive Inspection (NDI)
• Electrical Resistance (ER) Probes
• Material Test Coupons
• Galvanic Currents
• Cyclic Potentiodynamic Polarization (CPP)
• Linear Polarization Resistance
• Electro Chemical Noise (EN)
• Electrochemical Impedance Spectroscopy (EIS)
Indirect Measurements
• Potential
• Biological Count
• Hydrogen
• pH
• Temperature
• Conductivity
• Specific Ions
Periodic assessment is the most common method of corrosion monitoring
and can help to:
• Evaluate materials performance under specific service conditions
• Aid in proper material selection
• Evaluate and control the production process
• Provide necessary data for Residential Life Assessment
c. Improving Plant Reliability by Conducting Regular Safety Audits
BY Dr. Amar Nath Giri
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